Structural panel and method for making same

Abstract

A structural panel includes a rigid foam core, a spray foam on an exterior surface of the rigid foam core, and a first outer skin on the spray foam. The rigid foam core includes a tongue portion along a first longitudinal side face and a groove portion along a second longitudinal side face. A second outer skin is also on the spray foam.

We claim: 
     
       1. A structural panel, including:
 a rigid foam core; 
 a first spray foam on a first exterior surface of the rigid foam core; 
 a second spray foam on a second exterior surface of the rigid foam core; 
 a first outer skin on the first spray foam; and 
 a second outer skin on the second spray foam; 
 wherein the rigid foam core includes a tapered tongue portion along a first side face and the first spray foam and the second spray foam form a tapered groove portion along a second side face of the rigid foam core that is configured to accept the tapered tongue portion, and an entirety of the second side face of the rigid foam core is planar; 
 further wherein the rigid foam core is exposed for a length of the first side face and for a length of the second face of the rigid foam core. 
 
     
     
       2. The structural panel as set forth in  claim 1 , wherein:
 the tapered tongue portion extends along a first end face of the rigid foam core; and 
 the first spray portion and the second spray portion form a tapered groove portion along a second end face of the rigid foam core. 
 
     
     
       3. The structural panel as set forth in  claim 1 , wherein:
 the tapered tongue portion along the first side face is sized and shaped to matingly cooperate with a tapered groove portion along a second face of an adjacent structural panel; and 
 the tapered groove portion along the second side face is sized and shaped to matingly cooperate with a tapered tongue portion along a first face of an adjacent structural panel. 
 
     
     
       4. The structural panel as set forth in  claim 1 , wherein:
 at least one of the first and second outer skins covers at least a portion of the tapered tongue portion and the tapered groove portion. 
 
     
     
       5. The structural panel as set forth in  claim 1 , wherein:
 the rigid foam core is about 1 inch to about 5 inches thick; 
 the first portion of the spray foam is about ⅛ inch to about 1 inch thick; and 
 the second portion of the spray foam is about ⅛ inch to about 1 inch thick. 
 
     
     
       6. The structural panel as set forth in  claim 1 , wherein:
 the first outer skin is selected from the group consisting of metal, plastic, and fiber reinforced plastic and combinations thereof; and 
 the second outer skin is selected from the group consisting of metal, plastic, and fiber reinforced plastic and combinations thereof. 
 
     
     
       7. A composite insulative structural panel, including:
 a rigid foam core including a tapered tongue portion along a first longitudinal side face and having a second longitudinal side face which is planar; 
 a spray foam on an exterior surface of the rigid foam core and having an extension portion along at least a portion of the first longitudinal side face of the rigid foam core and at least two extension portions along the second longitudinal face of the rigid foam core to define a tapered groove portion that is configured to accept the tapered tongue portion; and 
 an outer skin around the spray foam; 
 wherein the rigid foam core is exposed for a length of a first side face and for a length of a second face of the rigid foam core. 
 
     
     
       8. The composite insulative structural panel as set forth in  claim 7 , wherein:
 the outer skin extends into the tapered groove; and 
 the outer skin contacts the rigid foam core in the tapered groove. 
 
     
     
       9. The structural panel as set forth in  claim 1 , wherein:
 the rigid foam core is selected from the group consisting of extruded polystyrene, expanded polystyrene, polyisocyanurate, polyurethane, and phenolic and combinations thereof; and 
 the spray foam is polyurethane based. 
 
     
     
       10. A structural panel, including:
 a rigid foam core having a top face, a bottom face, first longitudinal face, a first side face, a second longitudinal face and a second side face; 
 a first spray foam covering at least the top face and a second spray foam covering at least the bottom face; and 
 a first outer skin covering at least a portion of the first spray foam and a second outer skin covering at least a portion of the second spray foam; 
 wherein the rigid foam core includes a tapered tongue portion along at least the first side face, a tapered groove portion along the second side face, and the rigid foam core is exposed for a length of the first side face; 
 wherein the tapered groove portion along the second side face is configured to accept the tapered tongue portion along the first side face; 
 wherein the tapered groove portion along the second side face is formed by the first spray foam and the second spray foam; 
 further wherein the second longitudinal face and the second side face of the rigid foam core are planar. 
 
     
     
       11. The structural panel as set forth in  claim 10 , wherein the rigid foam core is extruded polystyrene and the spray foam is polyurethane based.